Method of making armature loops



March 17,, 1931. I v. G APPLE 1,796,423

' METHOD OF MAKING ABMATURE LOOPS Filed Nov. 15, 1928 2 Sheets-Sheet 2 /N VE N TOR.

Patented Mar. 17, 1931 UNlTE VINCENT G. APPLE, F DAYTON, QHIO METHOD OF MAKING ARMA'EUR-E LOOPS Application filed November 15, 1928.

This invention is shown, tho not claimed, in my co-pending application Serial Number 235,280 and relates to single tnrn bar wound armatures and is particularly adaptable to endwise entry of the winding.

One of the objects of my invention is to provide an integral winding unit comprising a loop having its open ends adapted to compose commutator segments.

Another object of my invention'is to provide an armature having a maximum of its core and winding material effectively employed, by producing core apertures of the most efiective contour and forming commer- 5 cially procurable material without waste into conductors that will conform to the contour of the core apertures selected and be readily assembled therein.

Further objects will be apparent to those skilled in the art upon consideration of the description and drawings wherein Fig. 1 is a plan View of a loop bent from round wire representing a turn of the winding.

' Fig. 2 is an end view of Fig. 1.

Fig. 3 represents a die by means of which the round cross section of the loop is changed to dilferent cross sections at parts of its length.

Fig. 4 shows the loop after it has been pressed in the die Fig. 3.

Fig. 5 is a cross section taken on line 55 Fig. l.

Fig. 6 is a cross section taken on line 66 Fig. 4t.

Fig. 7 is a cross section taken on line 7-7 Fig. d.

Fig. 8 shows how a leg of the outer layer may be paired with a leg of the inner layer of the winding to form a composite wedge shaped section.

Fig. 9 is a cross section taken on line 9-9 Fig. 8.

Fig. 10 is a cross section taken on line 1010 Fig. 8.

Fig. 11 shows a type of core aperture to which loops Fig. 4 are particularly applicable.

Fig. 12 shows a core with its apertures completely filled with loops Fig. 4.

erial No. 319,640.

Fig. 13 shows how the terminals of the en tire inner layer of the winding may be displaced radia ly inward.

Fig. 14 shows one pair of terminals after the terminal of the inner layer has been displaced radially inward.

Fig. 15 shows how the terminals are circumferentially displaced, the outer layer in one direction and the inner layer in the other direction. 0

Fig. 16 shows an armature after the outer layer of terminals has been displaced radially inward and the terminals brought together to compose a commutator.

Similar numerals refer to similar parts as thruout the several views. 7

Fig. 1 is a plan View and Fig. 2 an end view illustrating steps in the method of making a loop, wherein a predetermined length of round wire has been cut off and bent to loop formation as at 20, having extending therefrom a leg 21 which will later become part of theinner layer of the winding and which may therefore be called an inner conductor leg and a leg 22 which will later become a part of the outer layer of the winding and which may therefore be called an outer conductor leg. The ends 23 and 2% are bent slightly out of alignment with the remaining portions of the legs, the amount and direction of the bends being such that those ends will be equally distant from the armature axis and will extend parallel therewith.

After the loop has been formed, as in Figs. 1 and 2, it is placed in a die as in Fig. 3. The die here shown is for illustrative purposes only and consists of an upper portion 25 and a lower portion 26 between which the loop is pressed to change the cross sectional contour of-parts of its length, and to bring the loop to the form shown in Fig. l, wherein the cross section of the leg 21 has been changed from round to the form shown in Fig. 5, the other leg 22 having been left round as in Fig. 6 and the offset terminals 23 and 24 flattened to the shape shown in Fig. 7. By having olfset tl e terminals, as at 23 and 21. Fig. 1, the flattened ends 27 and 28 will occupy positions of equal distance from the core axis while the parts 21 and 22 will be at different when a leg 21 of ing broken away for clearness and While I distances therefrom, so that one l op is paired with a leg 22 of another loop they will arrange themselves substantially as shown in Fi wherein legs 21 and c) 7 Q2, relatively to tler position 111 the core are radial ,ther as 1n a, l. entire W111i mg 001 i 2 v a *1 icteu may be assemble l ltly entered into {L118 ape] 1 c c and simultaneously pushed in o space, as more clearly (escribed in my Patent to. L555, e l.

The core apert res may be lined with insnlat as as at 32, am portioning rib as at 33 may be p I or betvre n the two legs of a may be applien to the before entry into a core.

winding" has been assembled and pushed into p co in a core 3a, as shot-tn in Fig. 12, prey on must be made to rearrange the pairs of terminal ends 27-2S into other pairs, and to do this the entire setof inner layer terminals 2? is radially displaced in manner similar to the several terminals shown in the end view *ig. 13. The displacing of these terminals may be accomplished singly with a plunger as at 35, or, a tool may be constructed having a plurality of plunger-s to displace all terminals of the layer simultaneously.

A. iart section Fig. 1% shows the pair of terminals of an aperture after the inner layer terminal has beei radially displaced, and While I here show the inne layer of terminals as having been displaced *adially inward leaving the outer layer in normal position, it is obvious that as an alternative the outer layer may be displaced radially outwz rd leaving the inner layer in normal position or both layer may be displaced, the one inwardly and the other outwardly, the object being to separate the cir umterentially adeut flattened ends into cylindrical layers in order that the ends of one layer will not interfere with the ends of the other layer men circinnferential displacement of the at one layer relative to the ends of the un- ...ayer is taking place. lV ien the entire set of inner layer terminals h been radially displaced in a manner ina (heated in Figs. 13 and 14, all of the terminals are simultaneously moved, the outer layer circumterentially in one oirection and the inner layer circumterentially in the other direction, an amount corresponding to the front pitch of the winding leaving the terminal ends 27 and L8 extending parallel to the core axis.

Au armature with the Winding so bent is shown in 15, se eral outer layer bars beshow the layers as being bent equal amounts, they may be bent the one layer more than the other or, both layers may be bent different amounts in the same direction as 101 as the algebraic sum of the bends equals the front l i-ch desirec L11 order to pair the terminal ends 27 and 28 to form connnutator segments the terminals Q8 of the outer layer are now radially displaced, by a me hod similar to that employed in Fig. 13 to displace the inner layer, hus the terminals 27 and 28 are again it circumterentially adjacent in rearpairs shown in Fig. 16, Where both ayer terminals 28 and inner layer terare circinnierentially adjacent in l an n t brou g n llllCal formation of relatively small diameter. The ternnnals however, may be ed 1a a cricle of larger diameter by L nore spa ce between pairs, or by addpad to each pair.

i etal l Fhcn "he tops of the method of making an rrmture law progressed to the stage shown orn of binding means mu L iugal force, and SlllCG 1n held against centri my co-pendmg application Serial Number l descril e a process suitable for bindin these ends th same will not be herein repeat d, the met'iods therein disclosed may be applied equally Well to the present invention. it; notch as at 35, or, other projection which the binding means may engage, may be cut in the terminal ends either separately or after they are assembled as shown, or suitable projections may be form-eel on the tern'iinal ends in the die Fig. 8.

A single turn bar Winding is usually arranged in two concentric layers so that the portions oi the HTS which project beyond the ends of the core may extend, the one layer helically right handed and the other layer helically left hanoe l, and by such an arrangement a bar of one layer may join a widely separated bar of another layer thru their helically projecting ends without interference or contact with the helical ends of other bars of the Winding. It is therefore obvious that the conductors of be arranged in two cone uch portions of their length as are helically disposed, and that all other portions of the vinding may be composed of circumferentially adjacent parts in a single cylindrical layer.

lVhile I have shown and described a winding wherein the two layer configuration Fig. 9 extends not only thr iout the helically disposed parts but also thruout the portions contained in the core apertures, it is apparent that in the process of making the loop these aperture portions may be brought to posiuch a Winding need entric layers only at CTR and 124 Fig. 1, after which the die Fig. 3 may flatten these aperture portions to the cross sectional contour of the terminal ends Fig. 7. Such a winding would comprise helical portions in two concentric layers and aperture and terminal end portionscomposed of parts circumferentially adjacent in a single cylindrical layer. As it is sometimes considered advantageous to have wide thin conductors circumferentially adjacent in a core aperture rat er than thicker narrower conductors radially one above the other, the loops may be so made when the advantages to be gained justify.

While I have shown and described my method of making an improved winding as consisting of a number of steps in a given sequence, it is obvious that the steps need not necessarily be taken in the exact sequence indicated, but may be reversed or rearranged, or steps described as separately taken may be combined if so desired, and while I have shown round as a preferred form of wire for making loops comprising a winding, I do not wish to limit myself to the use of round wire, as wire of a modified form may be used, one feature of the invention consisting in providing a loop by using wire of uniform cross sectional contour thruout its length to form the conductors, and altering the cross sectional contour at parts of the length of the conductors, in such manner that those portions of the conductors which are necessarily arranged one radially above the other have cross sections adapted to that purpose while other portions which preferably occupy circumferentially adjacent positions are also suitably shaped, without altering the current carrying capacity at any point in the loop, yet maintaining such cross sectional contours at the altered portions that the composite contour of a pair of conductor legs thruout the length of a pair may substantialy conform to the shape of a winding aperture so as to be endwise enterable therethru.

Having described my invention, I claim 1. A method of making an integral winding loop for an armature, which consists of providing wire which substantially fits the outer half of a winding aperture, bending said wire in the form of a loop having two parallel spaced apart conductor bars joined at one end, said joined end being so formed that one bar of the loop is adapted to occupy a position in the winding nearer the core axis than the other bar, outwardly offsetting the end portion of that bar which is nearest the core axis and inwardly ofisetting the end portion of that bar which is farthest from the core axis, thus providing two parallel spaced apart ends which are equally distant from said core axis, and striking said loop in a die to provide a conductor bar of the outer layer of the winding, a conductor bar of the inner layer of the winding, and two radially equi-distant lugs suitable for commutator segments.

2. A method of making an integral winding loop for an armature which consists of providing wire of such cross sectional contour as will substantially conform to the entire circumferential width but only half the radial depth of a winding aperture, bending lengths of the wire to form loops and flattening the wire at the open ends of the loops to such a cross sectional contour as will substantially conform to the entire radial depth but only half the circumferential width of the said aperture for the purpose set forth.

3. A method of making an integral winding loop for an armature which consists of providing wire of a cross sectional area of substantially half that of a winding aperture and of a cross sectional contour to fit the aperture circumferentially, bending loops from said wire and reshaping the cross sectional contour of the wire at the open ends of the loops to half its original width and double its original depth for the reason disclosed.

4C. lhe method of making a winding loop for a two layer bar armature having conductor bars and commutator segments integral, which consists of bending a length of Wire of uniform cross section in the form of a loop having two spaced apart legs, the one adapted to take a position in the outer layer of the said armature, the other adapted to take a position in the inner layer of the said armature, offsetting the free ends of the legs until both ends are adapted to take positions equi-distant from the aXis of the said armature, and flattening the offset ends between planes which are substantially radial to the said armature.

5. The method of making a winding loop for a two layer bar armature having conductor bars and commutator segments integral, which consists of bending a length of wire of uniform cross section in the form of a loop having two spaced apart legs, the one adapted to take a position in the outer layer of the said armature and the other adapted to take a position in the inner layer of the said armature, offsetting the free ends of the legs until both ends are adapted to take aX- ially parallel positions equidistant from the aXis of the said armature, and pressing the offset ends between planes substantially radial to the said armature until said ends are substantially half their original thickness and double their original width.

In testimony whereof I hereunto set my hand.

VINCENT G. APPLE. 

